stef123

About Me

Very strong interests in car mechanics, general fabrication and welding, DIY, plumbing, electrical, electronics and all other things mechanical. Also interested in computers and motorbikes when the weather permits.

I hate decorating as I think we all do, but I do like bricklaying, plastering, kitchen fitting, general house renovations and groundworks - Passes the time

Here's one that's been baffling me and a mate for a while now. It's a 2004 focus 1.6 petrol. A good few months ago I changed a clutch and slave cylinder for him as a seal had burst inside the slave cylinder.

So I changed all three parts of the clutch, refitted the gearbox with new seals and fresh oil - All good, well it was for a few weeks.

So thinking the clutch maybe needed bleeding again I hooked up my pressure bleeder and pushed out a very small amount of air and let a good bit fluid pass. Everything seemed well again, good solid clutch pedal and no problems changing gear.

A couple of weeks passed and the pedal started doing the same thing again. So out with the pressure bleeder again, bled the system but no air this time but the pedal feels brand new again. ok, strange but its good. But this only lasted for another 2 weeks before the pedal went the same way. So I replaced the clutch master cylinder on the pedal (not knowing the age or condition I thought this could be suspect), again bled the system and the pedal is brilliant again.

Unfortunately the car went another 2 weeks before going the same way. My mate has put the pressure bleeder on the system for an hour with no loss of fluid or drop in pressure. But simply pressurising the reservoir returns the pedal to perfect working order again.

Really cant get my head round what is wrong here. Anyone any ideas or come across this before?

It struck me earlier that it would seem like less and less people are working on their own cars these days?

Is it because many systems are becoming too complicated and manufacturers are developing systems which require expensive 'special tools'?

I know many people have cars on lease deals so are covered by manufacturers warranty and only really need to have the car serviced before they trade in and get another new car so that must also contribute to a fair amount.

As the title suggests here is a few pics from a clutch change I done on a mk1 1.6 petrol focus at the weekend.
These are just pictures I took along the way, just a little insight into what your likely to encounter should you ever need to do this job. Not a difficult job, time consuming and horrible to do on the driveway, a lift would be so much nicer.

The mess when you spill about 2 litres of gearbox oil.. I didn't have time to get a picture of the oil as I was too busy trying to get sand lol;

New clutch fitted and lined up;

Brake fluid cleaned out and new slave cylinder fitted;

Old oil seals removed, note how they get a bit mangled trying to get them out;

New oil seal going in, I was trying to find my set of seal drivers at this point;

Gearbox read to fit back in;

View from underneath. It's not a hard gearbox to refit but it is awkward on your own, having to push it up and roll it round a bit;

And a nice new cv boot. Didn't have the right pliers with me so had to settle for a pair of end cutters instead. Only difference is the proper tool pushes the crimped bit flat - not an issue you need to worry about on the focus;